Compliance Tes 

Interkibl Dryer/Kihl Absorb• 

Testing Location: 

General Shale Brick, Inc. 

Plant 36 

770 Webster Road 

lue Ridge, Vi_•rgi_•ia 

Prepared for: 

Ms. Martha West 

General Shale Brick, Inc. 

3211 North Roan Street 

Johnson City, Tennessee 37601 

Date Submitted: 

September 2007 

Chris LeMay 

Project Manager 

E. Roberts Alley & Associates, Inc. 

1931 Central Parkway SW, Suite G 

Decatur, AL 35601 

Phone: (256) 351-0121 

Fax: (256) 351-0151 

ERA&A Project No. 2007-0524 

Prepared By: 
1,0 

1.1 

1.2 

1.3 

1.4 

2.0 

3.0 

3.1 

3.2 

3.3 

3.4 

General Shale Brick, Inc. 

Compliance Test Report 

Table of Contents 

TABLE OF CONTENTS 

Introduction ................................................ 1-1 

Facility and Source Descriptions ................................................................................................................. 1-1 

Project Team 

................................................................................................................................................ 1-1 

LaboratoD'. .................................................................................................................................................. 1-1 

Protocol/Method Deviations 1-1 

Summary of Results .................................................................................................................................... 2-1 

Testing Methodology. ....................................................................................... 3-1 

Methods & 2 Volumetric Flow Rate 3-1 

Method 3 Oxygen/Carbon Dioxide 3-1 

Method 4 Moisture Content 3-1 

Method 26A Hydrogen Chloride/Hydrogen Fluoride 3-1 

Appendix A 

Appendix B 

Appendix C 

Appendix D 

Appendix E 

APPENDICES 

Summary of Calculations 

Field Data 

Laboratory Data 

Quality Assurance/Quality Control Data 

Process Operating/Control System Data 

Table 2-1 

Table 3-1 

Fable ATable A-2 

Table A-3 

Table A-4 

LIST OF TABLES 

Summary of Compliance Testing Results 

Source Testing Methodology 

Inlet VFR Calculations 

Inlet Emission Calculations 

Outlet VFR Calculations 

Outlet Emission Calculations 

Proicci• (icnclal 5hale Brick. Inc. 2007-0524'( 'olnpliancc Repoli Page 
Introduction 
General SDale Bricy DTc. 

Compliance Test Report 

In troduction 

1.0 Introduction 

E. Roberts Alley & Associates, Inc. (ERA&A) was retained by General Shale Brick, Inc. (General Shale) to conduct 

emission testing at Plant 36 located in Blue Ridge, Virginia. Testing was conducted on the inlet and outlet of the 

Unit #6 absorber to demonstrate compliance with the hydrogen chloride (HC1) and hydrogen fluoride (HF) reduction 

efficiency (RE) requirements listed in the Virginia Department of Environmental Quality (DEQ) Permit Registration 

No. 20447, conditions 18 and 17. Previous pertbrmance testing for sulfur dioxide, HC1, HF and visible emissions 

was conducted in November 2006 and in March 2007 for HCI and HF. ERA&A personnel conducted the emission 

testing while General Shale provided all process operating and control system data to support the testing results. 

1.1 Facility and Source Descriptions 

General Shale's facility manufactures brick exterior building material. Shale and clay are mined, crushed and sent 

tlkrough a screening process prior to brick forming by extrusion. Once the brick is extruded, it is dried and fired in a 

tunnel kiln at approximately 2,000 °F. The facility operates two kilns (A & B) with a common exhatist. After being 

fired, the brick is cooled, packaged and shipped to various locations. 

The interkiln dryer/kiln emissions are controlled with an ohhnann type dry lime absorber (Unit #6). The exhaust 

stack is located outside the kiln building on the east side. 

1.2 Project Team 

The emission testing was conducted by Mr. Stacey Cunningham (Team Leader), Mr. Kem•y Boyd and Mr. Matt 

Hamilton. Mr. Chris LeMay served as ERA&A's Project Manager while Ms. Brandy Hughes served as the Report 

Coordinator. Ms. Martha West of General Shale served as ERA&A's tec|mical contact and coordinated the testing 

with facility operations. Mr. William Klepper from DEQ was present during the onsite testing. 

1.3 Laboratory 

HC1 and HF analyses were performed by Maxxam Analytical Inc. of Burlington, Ontario, Canada. 

1.4 Protocol/Method Deviations 

The were no deviations fi-om the Stack Test Protocol form submitted to DEQ on July 9, 2007 or U.S. EPA Reference 

Test Methods. 

c:Y, Pro ccls',Ocnei'al Shale tllick, Inc. 2()1)7-1i524 ('oniplial•cc Report Page I-I 
Summary of Results 
Compliance Test Report 

2.0 Snmmary of Results 

ERA&A conducted compliance testing on Unit #6 at the Blue Ridge, Virginia facility. Testing was conducted on 

August 22, 2007 and consisted of tlu-ee (3) 60-minute test runs on the inlet and outlet of the absorber. 

Table 2-1 provides a summary of the emission testing results. Any difference between the summary results listed in 

the following table and the detailed results contained in Appendix A is due to rounding for presentation. 

Table 2-1 

Summary of Compliance Testing Results 

Date 

Run Time, min 

Prodnction Data 

Brick Production, tons/hr 

Coal Usage, lbs/hr 

Gas Usage, scfh 

DLA Differential Pressure, in. WC 

Limestone Feed, lbs/hr 

Hydrogen Chloride Data 

Inlet Emission Rate, lbs/hr 

Outlet Emission Rate, lbs/hr 

Reductiou Efficiency, % 

Hydrogen Fluoride Data 

Inlet Emission Rate, lbs/hr 

Outlet Emission Rate, lbs/hr 

Reduction Efficieucy, % 

8/22/07 

60 

17.7 

1,367 

6,150 

0.35 

140 

4.2 

3.8 

30.1 

1.9 

8/22/07 

60 

17.7 

1,367 

6,150 

0.35 

140 

4.6 

3.7 

30.6 

1.9 

8/22/07 

60 

17.7 

1,367 

6,150 

0.35 

140 

4.9 

3.5 

29.7 

1.7 

8/22/07 

60 

17.7 

1,367 

6,150 

0.35 

140 

4.6 

3.6 

22 

30.1 

1.8 

94 

Pr•(icct• (icncral Shale Brick, Inc. 201/7-0524'Compliancc Repot1 Page 

General Shale Brick, Inc. 

3.0 Testing Methodology 

The emission testing program was conducted in accordance with the U.S. EPA Reference Test Methods listed in 

Table 3-l. Method descriptions are provided below, while quality assurance/quality control data is provided in 

Appendix D. 

Table 3-1 

Source Testing Methodology 

Volumetric Flow Rate (VFR) i-2 

Oxygen/Carbon Dioxide (O2/CO2) 3 Fyrite Analysis 

Moisture Content (BWS) 4 Gravimetric Analysis 

Hydrogen Chloride/Hydrogen Fluoride (HCI/HF) 26A Isokinetic Sampling 

3.1 Methods 1 & 2 Volumetric Flow Rate 

The sampling location and number of traverse (sampling) points •vere selected in strict accordance with EPA 

Reference Method 1. A full velocity traverse (EPA Reference Method 2) was conducted during each test run to 

determine the average stack gas velocity pressure, static pressure and temperature. The velocity and static pressure 

measurement system consisted of an S-type pitot tube and inclined manometer while the stack gas temperature was 

measnred with a K-type thermocouple and pyrometer. 

3.2 Method 3 Oxygen/Carbon Dioxide 

The oxygen and carbon dioxide concentrations were determined in accordance with EPA Reference Method 3. One 

(1) integrated Tedlar bag sample was collected during each test run. The bag sample was analyzed on site with a 

Eyrite 0•_/C02 analyzer. The Fyrite solutions were verified before and after testing by condncting a calibration 

check with EPA Protocol O2/CO2 gas. The remaining stack gas constituent was assumed to be nitrogen tbr the 

stack gas molecular weight determination. 

3.3 Method 4 Moisture Content 

The gas moisture contents were determined in accordance with EPA Reference Method 4. The gas conditioning 

trains consisted of a series of chilled impingers. Each impmger was pre and post-weighed on the same analytical 

balance to determine the amount of moisture condensed during each test run. 

3.4 Method 26A Hydrogen Chloride/Hydrogen Flnoride 

The hydrogen chloride and hydrogen fluoride concentrations were determined in accordance with EPA Refi•rence 

Method 26A. The complete sampling system consisted of a glass nozzle, heated glass-lined probe, hea•ed Teflon filter, 

gas conditioning train, pnmp and calibrated d•T gas meter. The gas conditioning train consisted of five (5) impingers 

contained in an ice/water bath. The first and second impingers contamecl 100 nit. of 0.1 N 11>504. the third and lburth 

contained 100 mL of 0.1 N NaOH and the fifth contained approximately 200 grams of silica gel. 

c:', Prqiects'•Gcncral Shale Brick. Inc, 2007-0524 ('omplim•cc Rcp•t Page 3- 
General Shale Brick, htc. 

Compliance Test Report 

Testing Methodology 

Following the completion of each test run, the sampling train was leak checked at a vacuum pressure greater than or 

equal to the highest vacuum pressure observed during the run. The impingers were weighed on an electronic 

balance to determine the amount of moisture gained. The contents of the first two (2) impingers were recovered in 

Sample Container 1. All connecting glassware, including the back half of the filter holder, was rinsed with DI water 

and these rinses added to Sample Container 1. The contents of impingers three (3) and four (4) were recovered in 

Sample Container 2. All comaecting glassware, from the inlet of the third impinger to the outlet of the fourth 

impinger, was rinsed with DI water and these rinses added to Sample Container 2. Container 2 •vill be held unless 

fi,•rther analysis is requested. 

All containers were sealed, labeled, and liquid levels marked for transport to Maxxam Analytics Inc. in Burlington, 

Ontario, Canada. The samples were analyzed by high performance liquid chromatography (HPLC). 

P)'(•iccl>, General Slmlc Brid,. Inc 20()7-0"•24 ('Oml•Iiancc Ncp•>rt Page 3-2 
,8) 

General Shale Brick, Inc. 

Compliance 7•sl Report 

Summwy of Calculations 

Example calculations are provided for Run 1-Inlet, unless otherwise noted, 

Meter Pressure (Pm), in. Hg 

Pm Pb +-- 

AH 

13.6 

where, 

Pb barometric pressure, in. Hg 

AH pressure differential of orifice in. H20 

Pm= 29.15 in. Hg+ 

1.163 in. H20 29.24 in. Hg 

13.6 in.H•,O/in. Hg 

Absolute Stack Gas Pressure (Ps), in. Hg 

ps Pb + 

Pg 

13.6 

where, 

Pb barometric pressure, in. Hg 

Pg static pressure, in. H•O 

Ps 29.15 in. Hg + 

O. 10 in.H:O 

13.6 in. H:O/in. Hg 

29.16 in. Hg 

Standard Meter Volume (Vmstd), dscf 

Vmstd 

17.647 x Y x Vm x Pm 

Tm 

where, 

Y meter con-ection factor 

Vm meter volume, cf 

Pm meter pressure, in. Hg 

Tm meter temperature, °R 

14nstd 

17.647 °R/in. Hg x 1.054 x 33.318 cf x 29.24in. Hg 33.836 dsqj 535.5°R 

Standard Wet Volume (Vwstd), scf 

l"wstd= O. 04707x Vlc 

where, 

Vlc volume of H20 collected, ml 

t'wstd 0,04707 ./?-V/mL x 57.0 mL 2.683 

PrRiccts General Shale Brick. Inc. 2007-0524 Compliance Rcporl Page A-I 
Moi•lure Fraction (BWS) 

BWg Vwstd 

(Vws, td + Vmstd) 

where, 

Vwstd standard wet volume, scf 

Vmstd standard meter volume, dscf 

BWS 2.683 scf 0.073 

2.683 scf + 33.836 dscf 

Moisture Content (MC), % 

MC BWS x 100 

where, 

BWS moisture fraction, dimensionless 

MC 0.073x lO0 7.3% 

Molecular Weight (DRY) (Md), lb/lb-mole 

Md (0.44 x COe) + (0.32 x 02) + (0.28 (100 CO, 02) ) 

where, 

CO•_ carbon dioxide concentration, % 

02 oxygen concentration, % 

Md =(0.44x3.0)+(O.32x16.3)+(0.28(lO0-3.0-16.3)) 29.13 lb/lb-mole 

Molecular Weight (WET) (Ms), lb/lb-mole 

MS Md (1 B WS) + 18 (B WS) 

where, 

Md molecular weight (DRY), lb/lb-mole 

BWS moisture fraction, dimensionless 

Ms 29.13 lb/lb-mole(l- O. 073)+18(0. 073) 28.321b/lb- moh 

General Shale Brick, Mc. 

Compliance Test Report 

Appendix A Summao, qf Calculations 

c:V',Prqiects'Gencral Shale Brick. Inc. 20074)524,Compliance Report Pa•c A-2 
General Shale Brick, h•c. 

Compliance Test Report 

Su•nmarv of Calculations 

Average Velocity (Vs), ft/sec 

Vs=85.49 x Cp k•l•avg, x 

PsxMs 

where, 

Cp pitot tube coefficient 

AP velocity head of stack gas, in. H20 

Ts absolute stack temperature, °R 

Ps absolute stack gas pressure, in. Hg 

Ms molecular weight of stack gas, lb/lb-mole 

85 49 'ft /db/lb mole) (in. Hg) / 843.9 °R Vs= •ec •] (°R)(in.H•O) x 0.84 x 0.372 in. H20 x 

•29.16 in. Hgx28.321b/lb-mo/e 27.0fi/sec 

Average Stack Gas Flow at Stack Conditions (Qa), acfm 

Qa 60x Vs x As 

where, 

Vs stack gas velocity, ft/sec 

As cross-secnonal area ot stack, ft" 

Qa 60sec/min x 27.0.fi/sec x 23.36fi e= 3.SE+O4acfm 

Average Stack Gas Flow at Standard Conditions (Qs), dscfm 

Qs=17.647 x Qa x (I-BWS) x 

]95 

where, 

Qa average stack gas flow at stack conditions, ft3/min 

BWS moisture fraction, dinaensionless 

Ps absolute stack gas pressure, in. Hg 

Ts absolute stack temperature, °R 

°R acf Qs=17.647-- x3.8E+04 x (1-0.073)x 

in. Hg 

29. 16i•. Hg 2. IE+ 04 ds'q'fin 843.9°R 

c:"Pro cots General Shale 13rick. Inc 2t}t 7- ":,24 ('ompliaacc P, Cl',Ort Page A-3 
/•\ ,• (•d•:•}•) •?,(• (• General Mmle Brick, h•c, 

Compliance Test Report 

Hydrogen Fhloride Concentration (elw) mg/dscm 

M #c• x35.313 

Vmstd× 1.OE + 03 

where, 

MnF hydrogen fluoride mass, ug 

Vmstd standard meter volume, dscf 

CHF 

360,000 ugx 35.313 .fi3/m 

33.836 &'cfxl .OE + 03uglmg 

375.7 mgl&'cm 

Hydrogen Flnoride Emission Rate (ERm:), lbs/hr 

ERHF MtICl Qs 60 

Vmstd 4,54E 08 

where, 

M•v hydrogen fluoride mass, ug 

Vmstd standard meter volume, dscf 

Qs stack gas flow rate at standard conditions, dscfm 

60,000 ug 2. E 04&.@n 60 inin/hr 

30. lbs hr 

33.836 dscf 4.54 L,'+ 08 ug/lb 

Hydrogen Fluoride Reduction Efficiency (RE), % 

RE= 

•Rh•/e ERoutlet 

ERlnle x 100 

where, 

ERI,•I•:• inlet HF emission rate, Ibs/hr 

ERo,,•l•t outlet HI:' enfission rate, lbs/lu" 

•30.1lbs/hr- 1.8lbs'lhr 

RE 

• •.•--/•s-//•r x t00 93.9% 

HCI emission calculations were perfbrmed in a similar manner to HF emission calculations. 

Pmicct,, Gcnc•nl Shale Brick Inc 20(17-(1524 ('omplial•cc Rcporl Page A-4 
Genera/Shcde Brick, Inc. 

Compliance Test Report 

Appendix A Summwy of Calculations 

Table A-1 

Iiile• VFR Calculations 

Run Number Run Run 2 Run 3 Average 

Date 08/22/07 08/22/07 08/22/07 

3tart Time 8:01 AM 9:52 AM 11:40 AM 

Stop Time 9:07 AM 11:02 AM 12:50 PM 

Run Time, rain 60 60 60 60 

Point 0.12 0.10 0.10 0.11 

Point 2 0.14 0.11 0.11 0.12 

Point 3 0.14 0.12 0.11 0.12 

Point 4 0.12 0.13 0.12 0.12 

Point 5 0.13 0.14 0.13 0.13 

Point 6 0.15 0.17 0.18 0.17 

Point 7 0.15 0.20 0.20 0.18 

Point 8 0.15 0.22 0.21 0,19 

Point 9 0.13 0. 0.11 0.12 

Point 10 0.13 0.11 0.11 0.12 

Point 11 0.11 0.12 0.12 0.12 

Point 12 0.12 0.11 0.11 0.11 

Point 13 0.11 0.12 0.13 0.12 

Point 14 0.13 0.14 0.14 0.14 

Point 15 0.14 0.16 0.14 0.15 

Point 16 0.18 0.17 0.18 0.18 

Point 17 0.12 0.11 0.1l 0.I1 

Point 18 0.11 0.11 0.11 0.11 

Point 19 0.11 0.14 0.12 0.12 

Point 20 0.13 0.14 0.12 0.13 

Point 21 0.15 0.19 0.17 0.17 

Point 22 0.17 0.19 0.16 0.17 

Point 23 0.20 0.23 0.21 0.21 

Point 24 0.21 0.25 0.22 0.23 

Square Root of Delta P 

Pitot Tube Coefficient 

Barometric Pressure, in. Hg 

Static Pressure, in. H20 

Stack Pressure, in. Hg 

Stack Depth, in. 

•tack Width, in. 

9tack Cross-sectional Area, ft 

iTemperature, °F 

Moisture Content, % 

CO2 Concentratiou, % 

02 Concentration, % 

Molecular Weight. lb/lb-mole (dry) 

iMolecular Weight, lb/Ib-mole (wet) 

Velocity, ft/sec 

(in. WC) 0.372 0.383 0.374 0.377 

(Cp) 0.84 0.84 0.84 0.84 

(Pb) 29.15 29.15 29.15 29.15 

(Pg) 0.10 0.11 0.10 0. I0 

(Ps) 29.16 29.16 29.16 29.16 

(Ds) 58.0 58.0 58.0 58.0 

(Ws) 58.0 58.0 58.0 58.0 

(As) 23.36 23.36 23.36 23.36 

(Ts) 383.9 377.5 373.4 3•8•2 

(MC) 7.3 7.2 7.4 73 

(CO2) 3.0 3.0 3.0 3.0 

(02) 16.3 16.3 16.5 

(Md) 29.13 29.13 29.14 29.13 

(Ms) 28.32 28.33 28.32 28,32 

(Vs) 27.0 27.7 27.0 27.2 

&t Stack Conditions, acfin 

•kt Standard Conditious. dscfln 

(Qa) 37,857 38,828 37,866 38iI84 

(Qs) 21,398 22,139 21,649 

Prt•icct> General Shale Bdck. Inc. 2007-0524,•Complial]ce Rq•orl Page 
Genera/Skale Brick, blc. 

Compliance Test Report 

Appendix A Summary of Calculations 

Table A-2 

i•let Emission Calculations 

Run Number Run Run 2 Run 3 Average 

Date 

Start Time 

Stop Time 

Run Time, lnin 

Barometric Pressure, in. Hg 

Meter Correction Factor 

3rifice Calibration Value 

Meter Volume, f•3 

Meter Temperature, °F 

Meter Orifice Pressure, in. WC 

Volume H20 Collected, mL 

Nozzle Diameter, in 

Area of Nozzle, ft 

Hydrogen Chloride Mass, pg 

Hydrogen Fluoride Mass,/.tg 

Standard Meter Volume, ft 

Standard Water Volume, ft 

Moisture Fraction 

Meter Pressure, in Hg 

Volume at Nozzle, ft 

[sokinetic Sampling Rate, (%) 

•GM Calibration Check Value, (+/- 5%) 

08/22/07 08/22/07 08/22/07 

8:01 AM 9:52 AM 11:40 AM 

9:07 AM 11:02 AM 12:50 PM 

({9) 60 60 60 60 

(Pb) 29.15 29.15 29.15 29.15 

(Y) 1.054 1.054 1.054 1.054 

(Delta H@) 1.909 1.909 1.909 1.909 

(Vm) 33.318 35.577 35.283 34.726 

(Tin) 75.5 85.8 92.0 84.4 

(Delta H) 1.163 1.312 1.274 1.250 

(Vlc) 57.0 58.3 58.7 58.0 

(Dn) 0.340 0.340 0.340 0.340 

(An) 0.00063 0.00063 0.00063 0.00063 

(MHcl) 50,000 56,000 59,000 55,000 

(MHI:) 360,000 370,000 360,000 363,333 

(Vmstd) 33.836 35.456 34.767 34.686 

(Vwstd) 2.683 2.744 2.763 2.730 

(BWS) 0.073 0.072 0.074 0.073 

(Pm) 29.24 29.25 29.24 29.24 

(Vn) 59.896 62.176 60.789 60.953 

(I) 97.7 98.9 99.1 98.6 

(Y,•a) 1.3 1.2 1.2 1.2 

Hydrogen Chloride Concentration, mg/dscm (C•c.i) 

Hydrogen Chloride Concentration, ppmvd (CH(,i)ppln 

Hydrogen Chloride Emission Rate, lbs/hr (ER•c0 

Hydrogen Fluoride Concentration, mg/dscm (Cm-) 

Hydrogen Fluoride Concentration, ppmvd (CHF)ppm 

[-Iydrogen Fluoride Emission Rate, lbs/hr (ERHv) 

52.2 55.8 59.9 56.0 

34.4 36.7 39.5 .•6:9 

4.18 4.63 4.86 4:56 

375.7 368.5 365.7 370.0 

451.6 442.9 439.5 444:7 

30.11 30.56 29.65 30ili 

c:'..Pro ccts:•Gcncml Shale Brick, hm20[)7-0524'Coinpliancc Report 
Table A-3 

Outlet VFR Calculations 

General Shale Brick, lnc. 

Compliance Test Report 

Appendix A Summary q/ Calculations 

Run Number Run Run 2 Run 3 Average 

Date 8/22/07 8/22/07 8/22/07 

Start Time 8:01 AM 9:52 AM 11:40 AM 

Stop Time 9:06 AM 10:57 AM 12:44 PM 

Run Time, min 60 60 60 60 

Point 0.13 0.12 0.12 0.12 

Point 2 0.13 0.17 0.13 0.14 

Point 3 0.15 0.16 0.15 0.15 

Point 4 0.17 0.15 0.16 0.16 

Point 5 0.15 0.13 0.15 0.14 

Point 6 0.t0 0.10 0.10 0.10 

Point 7 0.11 0.13 0.13 0.12 

Point 8 0.13 0.12 0.14 0.13 

Point 9 0.15 0.16 0.15 0.15 

Point 10 0.16 0.17 0.15 0.16 

Point 11 0.14 0.18 0.12 0.15 

Point 12 0.10 0.11 0.10 0.10 

Square Root ofdP 

?itot Tube Coefficient 

3arometric Pressure, in. Hg 

Static Pressure, in. H20 

Stack Pressure, in. Hg 

Stack Depth, in. 

Stack Cross-sectional Area, f't 

l"emperamre, °F 

Femperature, °R 

Moisture Content, % 

202 Concentration, % 

D2 Coucentration, % 

Molecular Weight, lb/lb-mole (dry) 

Molecular Weight, lb/lb-mole (wet) 

Velocity, ft/sec 

(in. WC) •/z 0.366 0.375 0.364 0.368 

(Cp) 0.84 0.84 0.84 0.84 

(Pb) 29.15 29.15 29.15 29.15 

(Pg) 0.12 0.12 0.11 0.12 

(Ps) 29.16 29.16 29.16 29.16 

(Ds) 71.50 71.50 71.50 71.50 

(As) 27.88 27.88 27.88 27.88 

(Ts) 354. 359.5 357.4 35•i0 

(Ts) 814.1 819.5 817.4 817.0 

(MC) 4.4 6.8 7.2 6!1 

(CO2) 2.8 3.0 3.0 2.9 

(02) 16.8 16.5 16.8 16i7 

(Md) 29.12 29.14 29.15 29.14 

(Ms) 28.63 28.38 28.35 28.45 

(Vs) 26.0 26.8 26.0 26.3 

At Stack Conditions, acfln 

At Standard Conditions, dsc fm 

(Qa) 43.442 44.811 43.504 43919 

(Qs) _•6,_?5l 26.224 25.414 "•z>•96• 

',Pro ects',Gencral Shale Brick. Inc. 2007-0524 ('•,ml•liancc Report Page A-7 
Appendix A Summary of Calculations 

Table A-4 

Ontle{ Emission Calculations 

un Run Run 2 Run 3 Number 

ate 08/22/07 08/22/07 08/22/07 

art Time 8:01l AM 9:52 AM 11:40 AM 

;top Time 9:06 AM 10:57 AM 12:44 PM 

• Pressure, in. Hg 

Meter Correction Factor 

Orifice Calibration Value 

Meter Volume, ft 

Meter Temperature, °F 

Meter Temperature, °R 

Meter Orifice Pressure, in. WC 

Volume H20 Collected, mL 

Nozzle Diameter, in 

Area of Nozzle, ft 

Hydrogen Chloride Mass, ug 

Fluoride Mass, ug 

Average 

(f•) 60 60 60 60 

(Pb) 29.15 29.15 29.15 29.15 

(Y) 1.018 1.018 1.018 1.018 

(AH @) 2.300 2.300 2.300 2.300 

(Vm) 43.419 45.230 43.916 44.188 

(Tin) 78.3 89.8 96.1 88.1 

(Tm) 538.3 549.8 556.1 548.1 

(AH) 2.145 2.364 2.178 2.229 

(Vlc) 41.2 66.8 68.7 58.9 

(Dn) 0.375 0.375 0.375 0.375 

(An) 0.00077 0.00077 0.00077 0.00077 

(M•c.0 46,000 46,000 43,000 32,100 

(MHF) 23,000 24,000 21,000 22,667 

Meter Volume, ft (Vmstd) Standard Water Volume, ft (Vwstd) 

Moisture Fraction (BWS) 

Meter Pressure, in Hg (Pro) 

Volume at Nozzle, ft (Vn) 

[sokinetic Sampling Rate, (%) (I) 

DGM Calibration Check Value, (+/- 5%) (Yq,•) 

42.471 43.335 41.583 42.463 

1.939 3.144 3.234 2.772 

0.044 0.068 0.072 0.061 

29.31 29.32 29.31 29.31 

70.263 74.026 71.200 71.829 

98.0 100.1 99.2 99.1 

0.2 -1.5 -1.1 -0.8 

38.2 37.5 36.5 37.4 

25.2 24.7 24.0 

3.76 3.68 3.48 3i64 

19. 19.6 17.8 18.8 

23.0 23.5 21.4 22•6 

1.88 1.92 1.70 1183 

Hydrogen Chloride Concentration, mg/dscm (Cmq) 

Hydrogen Chloride Concentration, ppmvd (C• 

Hydrogen Chloride Emission Rate, Ibs/hr (ERI 

Hydrogen Fluoride Concentration, mg/dscm (C•I:) 

Hydrogen Fluoride Concentration, ppmvd (C• 

Hydrogen Fluoride Emission Rate, lbsihr (ERuF) 

ProiccIs General Shah: [:Iri,.'k. Inc 2007-(1524 ('omplim•cc Rcp•)rl Page A-8 
Appendix 
l,ncation: GS (Plant 36)- Roannke, VA 

Date: {}8/21/07 

Source: DLA lulet 

Project No.: 2007-0524 

Engineering Environmental- Health & Safety- Surveying 

Method Velocity Traverse Data 

Distaoee fl'om far wall to ontside of port: 62.00 iu. 

Nipple length: 4.00 in. 

Depth of Duct (Ds): 58.00 in. 

Width of Duct (Ws): 58.00 in. 

Cross Sectional Area of Duct (As): 23.36 

No. of ports: 3 

Up-stream (A): 2.8 ft. 

Down-stream (B): 15.0 ft. 

Equivalent Diameter: 58.0 

Number of traverse points total: 

0,6 l)nct Diameters 

3.1 Duct Diameters 

24 

Traverse 

point Number 

4 

6 

7 

9 

10 

II 

12 

LOCATION OF TRAVERSE POINTS 

RECTANGULAR STACKS 

Number of traverse ports diameter 

2 3 4 6 7 8 9 10 11 12 

25.0 16.7 12.5 10.0 8,3 7.1 6.3 5.6 5.0 4.5 4.2 

75.0 50.0 37.5 30.0 25.0 21.4 18,8 16.7 15.0 13.6 12.5 

63.3 62.5 50,0 41.7 35.7 31.3 27.8 25.0 31.8 20.8 

87.5 70.0 58.3 50.0 43.8 38.9 35.0 22.7 29,2 

90.0 75.0 64.3 56.3 50.0 45.0 40.9 37.5 

91.7 78.6 68.8 61.1 55.0 50.0 45.8 

92.9 81.3 72,2 65.0 59.1 54.2 

93.8 83.3 75.0 68.2 62.5 

94.4 85,0 77.3 70.8 

95.0 86.4 79.2 

95.5 87.5 

95.8 

*Percent o[stack diameter fi'om inside wall to h'averse point. 

EXAMPLE 

RECTANGULAR STACK 

CROSS SECTION 

DIVIDED INTO 12 EQUAL 

AREAS, WITH TRAVERSE 

AT CENTROID 

•,linimum number of traverse points for particulate traverses 

Duct Diameters Upstream liom Flow Distmbance* (Distance A) 

24 25 

20 

--I 

(Bend.f!xpansion. ('o•llraction. 9 

4 6 7 9 10 

Ducl l)iamelers I)o•nsmon li'om Flow Disturbance* (Distance B) 

Traverse % of 

Point Diameter 

6.3 

2 18.8 

3 31.3 

4 43.8 

5 56.3 

6 68.8 

7 81.3 

8 93.8 

10 

11 

12 

Distaoce fron Distance from 

outside of inside wall 

port 

3.65 7.65 

10.90 14.90 

18.15 22.•5 

25_40 29.40 

32.65 36.65 

39.90 43.90 

47.15 51,15 

54.40 58.40 

Notes: 

Test Personnel (signa{nre/date) "g ture/date) 
I=ocalJ'on: (;S (t>hlnt 36) Roanoke, VA 

l)alc: 08/21/07 

Source: DLA Inlet 

Project No.: 2007-0524 

Method 1 Verification of Absense of Cyclonic Flow 

(Section 11.4) 

Engineering Environmental. Health & Safety. Surveying 

Sample Point aP @ Reference Angle (AP=0) 

1 0.31 8 

2 0.28 11 

3 0.24 10 

4 0.21 

5 0.17 

6 0.16 

7 0.15 

8 0.13 

9 0.24 

10 0.20 

11 0.16 

12 0.14 

13 0.14 

0.14 

0.15 

14 

15 

16 0.10 

17 0.19 

18 0.16 

19 0.14 

20 0.13 

21 0.14 

22 0.14 

0.15 

9 

9 

10 

9 

11 

6 

8 

10 

12 

11 

7 

6 

8 

7 

9 

9 

10 

23 

24 0.11 9 

25 

26 

27 

28 

29 

3O 

31 

32 

33 

34 

35 

36 

37 

38 

39 

40 

Average 0.17 

11 

9.0 

QA/QC Reviewer 
Location: GS (Plant 36) Roanoke, VA Source: DLA Inlet 

Project No.: 2007-0524 

Engineering Environmental. Health & Safety. Surveying 

Method 3 Gas Analysis Data 

Run 1 Date: 8/22/07 

Analysis Nnmber % CO2 % Oz % Nz 

1 3.0 16.0 81.0 

2 3.0 16.5 80.5 

3 3.0 16.5 80.5 

Average 3.0 16.3 80.7 

Repeatability (P/F): P P P 

Run 2 Date: 8/22/07 

Analysis Nnmber % COz % Oz % Nz 

1 3.0 16.0 81.0 

2 3.0 16,5 80.5 

3 3.0 16.5 80.5 

Average 3,0 16.3 80.7 

Repeatability (P/F): P P P 

Run 3 Date: 8/22/07 

Analysis Number % COz °/o Oz °/o N2 

1 3.0 16,5 80.5 

2 3.0 16.5 80.5 

3 3.0 16.5 80,5 

Average 3.0 16.5 80.5 

Repeatability (P/F): P P P 

Acceptability for Orsat Repeat Analys!.s. 

C02 > 4% + 0.3% 

CO2 -< 4% + 0.2% 

02 > 15%--- + 0.3% 

0 < 15% ----+ 0.2% 

Ambient Check Analysis Type 

O•_ 20.5 % Orsat report to 0.1% 

CO• 0_0 % Fyrite report to 0,5% 

QA/QC Reviewer 
Location: GS (Plant 36) Roanoke, VA 

Date(s): 08/22/07 

,qource: DLA hllet 

Project No. 2(107-0524 

Ez•q•heerinq Enwkonmental. Health & Safety. Su•evinq 

Method 4 Moisture Data 

Sample ID: Ran Filter ID: Date: 8/22/07 

IMPINGER VOLUME, ml 

H2SO4 

100.0 

124.0 

24.0 

hnpinger Color: 

Silica Gel Condition: 

H2SO4 NaOtl NaOH Silica 

6 7 Total 

100.0 100.0 100.0 231,5 631.5 

120.0 I04.0 100.0 240.5 688.5 

20.0 4.0 0.0 9.0 57.0 

Clear Labeled? Yes 

OK Sealed? Yes 

Sample ID: Run 2 Filter ID: Date: 8/22/07 

IMPINGER VOLUME, nil 

2 3 4 5 6 7 8 Total 

H2SO4 H2SO4 NaOlt NaOlt Silica 

100.0 100.0 100.0 100.0 242.7 642.7 

140.0 108.0 

40.0 8.0 

102.0 

2.0 

100.0 

0.0 

251.0 

8.3 

hnpinger Color: Clear l•abeled? Yes 

Silica Gel Condition: OK Sealed? Yes 

Sample ID: Run 3 Filter D: Date: 8/22/07 

701.0 

58.3 

IMPINGER VOLUME, nil 

eats H2SO4 

100.0 

146.0 

46.0 

hnpinger Color: 

Silica Gel Condition: 

H2SO4 

100.0 

NaOIl 

100.0 

NaOH 

100.0 

Silica 

227.8 

102,0 102.0 101.0 235.5 

2.0 2.0 1.0 7.7 

Clear Labeled? Yes 

OK Sealed? Yes 

Total 

627.8 

686.5 

58.7 

Comments: 

Chain of Custody Complele? 

Prepared By: 

Analyst: 

Yes Date: 08/22/07 

Stacev Coaningham Dale: 08/22/07 

Stace• Cunninglmm Date: 08/22/07 

Test l'ers•flnel (signature/datc) 
I.ocation: GS (Plant 36) Roanoke, VA Start Time: 8:01 AM I•,un 

End Time: 9:07 AM 

A-I 

2 

3 

4 

5 

6 

7 

2 

4 

6 

7 

C-1 

2 

3 

4 

6 

8 

Date: 08/22/07 

S'TACK DATA (EST) 

% Moisture: 8.5 % est. 

EQUIPMENT 

METER BOX: 1376 

Source: DLA Inlet 

Project No.: 2007-0524 

Barometric: 30.00 inHg 

Static Press: 0.12 in WC 

Stack Press: 30.01 in Hg 

%CO2: 3.5 % 

%02: 16.5 % 

%N2/CO: 80.0 % 

Md: 29.22 Ib/lb-mole 

Ms: 28.27 lb/lb-mole 

STACK DATA (EST) 

Y: 1.054 

DH@: 1.909 

PITOT ID: PR-14 

Cp: 0.84 

NOZZLE ID: G-001 

Dn: 0.340 

Depth/Width (in): 58.0 58.0 

Stack Area: 23.36 f( 

Est. Tin: 90 °F 

Est. Ts: 334 °F 

Est. dP: 0.17 in WC 

Est. Dn 0.356 inches 

FILTER NO. 

N/A 

LEAK CHECKS 

Pre Mid Post 

Leak Rate: 0.003 0.000 cfin 

Pump Vacnum: 15 4 in Hg 

Pitot Tube: Pass Pass 

MOISTURE DATA 

Total Liquid Vol. (ml) 

57.0 

K-FACTOR 

9.093 

Volume Corrections 

#1 cf 

#2 cf 

Total ef 

Sam pie Time Dry Gas Meter 

(minutes) Reading (ft 3) 

Begiu End 

0.00 2.50 891.745 

2.50 5.00 893.100 

5.00 7.50 894,400 

7.50 10.00 895.802 

10.00 12.50 897.092 

12.50 15.00 898.438 

15.00 17.50 899.914 

17.50 20.00 901.382 

20,00 22.50 902.790 

22.50 25.00 904.166 

25.00 27.50 905.490 

27.50 30.00 906.750 

30.00 32.50 908.070 

32.50 35,00 909.300 

35,00 37.50 910.650 

37,50 40,00 912.015 

40.00 42.50 913.563 

42.50 45.00 914.910 

45.00 47.50 916.156 

47,50 50.00 917.400 

50.00 52.50 918.760 

52.50 55.00 920.200 

55.00 57.50 921.7t0 

57.50 60.00 923.416 

60.00 925.063 

Final DGM: 925.063 

Gas Temperatures (°F 

Pitot DGM Orifice Press. 

Tube Average Stack DH (in. H20) 

Arab. Amb. 

70 73 Ideal Actual 

0.12 70 370 1.01 1.01 

0.14 71 373 1.17 1.16 

0.14 72 383 1.16 1.16 

0.12 72 388 0.99 0.99 

0.13 72 394 1.07 1.07 

0.15 73 399 1.22 1.22 

0.15 74 403 1.22 1.22 

0.15 74 386 1.25 1.25 

0.13 73 358 1.11 1.12 

0.13 74 347 1.13 1.14 

0.11 75 369 0.93 0.93 

0.12 75 375 1.01 1.01 

0.11 76 385 0.92 0.92 

0.13 76 392 1.08 1.08 

0.14 76 396 1.15 1.15 

0.18 77 402 1.47 1.47 

0.12 77 355 1.04 1.04 

0.11 78 376 0.93 0.92 

0.11 78 384 0.92 0.93 

0.13 78 387 1.09 1.08 

0.15 79 392 1.25 1.25 

0.17 80 395 1.41 1.41 

0.20 80 400 1.65 1.65 

0.21 81 404 1.73 1.73 

Gas Temps CF) 

Pump 

Vac hnp. Vs 

(in. Probe Filter Exit XAD % ISO (fps) 

Hg.) 

73 74 75 

2 260 261 66 N/A 105.3 24.6t 

2 260 260 59 N/A 93.5 26.63 

3 260 259 46 N/A 101.3 26.79 

2 260 261 46 N/A 100.9 24.87 

3 260 260 49 N/A 101.6 25.98 

3 261 26t 49 N/A 103.8 27.99 

3 260 26t 50 N/A t03.3 28.05 

3 260 260 52 N/A 98.1 27.78 

3 260 260 56 N/A 101.4 25.43 

3 260 261 52 N/A 96.8 25.25 

3 261 261 52 N/A t01.2 23.55 

3 260 261 53 N/A 10t.9 24.68 

3 259 262 53 N/A 99.6 23.77 

3 260 258 53 N/A 101.0 25.95 

3 260 260 53 N/A 98.6 26.99 

3 260 265 53 N/A 98.9 30.71 

3 263 261 56 N/A 102,4 24.38 

3 262 259 54 N/A 99.9 23.64 

3 252 260 54 N/A 100.3 23,76 

3 254 260 52 N/A 101.0 25.87 

3 261 259 52 N/A 99.8 27.87 

4 262 263 53 N/A 98.3 29.73 

4 260 259 53 N/A 102.7 32.34 

4 262 260 53 N/A 96.9 33.21 

" Orsat Analyzer ;• Fyrite SuperSat'd 

Run Time 

60.1t rain 

Vm DP (WC) Tm Ts 

0.944 tn 3.52 nun 24.1 °C 195.5 °C 

33.318 fr 0.14 in 75.5 °F 383.9 °F 

Vms,i Vws,i % tlzO Qsd 

0.958 dscm 0.076 scm (meas.) 606 dscmm 

33.836 dscf 2.683 scf 7.3 21,398 dscfm 

Test Person nel (signatnre/date) 

Max DII (WC) %150 Vs 

Vac. 29.538 m•n 8.23 m/s 

4 !.163 in 97.7 27.01 ft/s 

Qsw Qa 

654 scm•u 1,072 acmm 

23,083 scfm 37,857 acfm 

Testeeam Lea•'fer (signa/nre/date) 

-1.3 
Localion: GS (Plant 36) Roaooke, VA Start Time: 9:52 AM Rua 2 

Date: 08/22/07 End Time: 11:02 AM 

Source: DLA hflct 

Project No.: 2007-0524 

STACK DATA (EST) 

% Moisture: 7.3 % est. 

Barometric: 30.00 in Hg 

Static Press: 0.12 inWC 

Stack Press: 30.01 in Hg 

%CO2: 3.5 % 

%02: 16.5 % 

%N2/CO: 80.0 % 

Md: 29.22 lb/Ib-mole 

Ms: 28.40 Ib/lb-mole 

EQUIPMENT 

METER BOX: 1376 

Y: 1.054 

Dtt@: 1.909 in I-t20 

PITOT ID: PR-14 

Cp: 0.84 

NOZZLE ID: G-001 

Dn: 0.340 in 

Depth/Width (in): 58.0 58.0 

Stack Area: 23.36 ft 

STACK DATA (EST) 

•st. Tin: 75 °F 

Est. Ts: 384 °F 

Est. dP: 0.14 in WC 

Est. Dn: 0.384 inches 

FILTER NO. 

N/A 

LEAK CHECKS 

Pre Mid Post 

Leak Rate: 0.000 0.000 cfm 

Pump Vacnum: 12 6 in Hg 

Pitot Tube: Pass Pass 

Gas Temperatures (°F) 

DGM Orifice Press. Pump 

MOISTURE DATA 

Total Liquid Vol. (ml) 

58.3 

K FACTOR 

8.513 

Volume Correctioos 

#1 cf 

#2 cf 

Total cf 

Dry Gas Meter 

Reading (ft 3) 

• Pitot 

"• Sample Time 

DP Vac 

• (minutes) Average Stack DH (in. H20) (in. 

• Arab. Arab. Hg.) 

Begin End 0n. HXO) Ideal Actnal 

A-I 0.00 2.50 925.563 0.10 79 382 0.86 0.87 2 260 259 

2 2.50 5.00 926.782 0.11 80 362 0.97 0.97 2 262 261 

3 5.00 7.50 928.060 0.12 80 345 1.08 1.08 2 263 260 

4 7.50 10.00 929.400 0.13 81 364 1.15 1.14 3 260 259 

5 10.00 12.50 930.794 0.14 82 374 1.22 1.22 3 260 263 

6 12.50 15.00 932,233 0.17 82 381 1.47 1.48 2 261 263 

7 15.00 17.50 933.788 0.20 83 387 1.72 1.72 3 262 264 

8 17.50 20.00 935,480 0.22 85 391 1.89 1.90 4 261 264 

B-I 20.00 22.50 937.294 0,11 82 363 0.97 0,97 3 261 262 

2 22.50 25.00 938,590 0.11 85 366 0.98 0.98 3 263 259 

3 25.00 27.50 939.843 0.12 85 376 1.05 1.06 3 260 263 

4 27.50 30.00 941.168 0.11 86 379 0.96 0.97 3 261 264 

5 30.00 32.50 942.488 0.12 88 385 1.05 1,05 3 261 263 

6 32.50 35.00 943.795 0.14 87 389 1.21 1,22 3 263 261 

7 35,00 37.50 945.270 0.16 87 393 1.38 1.38 3 262 261 

8 37.50 40.00 946.788 0.17 88 396 1.46 1.46 4 261 264 

C-I 40,00 42.50 948.334 0.11 87 368 0.98 0.97 3 260 263 

2 42.50 45.00 949.640 0. II 89 375 0.97 0.98 3 263 264 

3 45.00 47.50 950.915 0.14 89 379 1.23 1.24 3 262 261 

4 47.50 50.00 952.400 0.14 90 372 1.24 1.25 3 261 263 

5 50.00 52.50 953.870 0.19 90 385 1.66 1.66 4 263 262 

6 52.50 55.00 955,560 0.19 91 389 1.66 1.66 4 261 262 

7 55.00 57.50 957.290 0.23 92 396 1.99 2.00 5 263 260 

8 57.50 60.00 959,145 0,25 92 362 2.25 2.26 6 261 261 

60.00 961.140 

Final DGM: 961.140 

Gas Temps (°F) 

Imp. Vs 

Probe Filter Exit XAD % ISO 

(fps) 

65 N/A 101.6 22.57 

60 N/A 100.2 23.39 

52 N/A 99.6 24.18 

50 N/A 100,5 25_46 

50 N/A 100.4 26.58 

51 N/A 99.0 29.41 

52 N/A 99.5 32.02 

52 N/A 101,6 33.66 

56 N/A 101.3 23.40 

58 N/A 97.6 23.45 

55 N/A 99.4 24.64 

56 N/A 103.4 23.63 

57 N/A 98.1 24.77 

57 N/A 102.9 26,82 

62 N/A 99.4 28.74 

56 N/A 98.2 29.67 

66 N/A 101.5 23.48 

59 N/A 99.1 23.57 

59 N/A 102,6 26.66 

61 N/A 101.0 26.55 

57 N/A 100.5 31.17 

58 N/A 103,0 31.24 

59 N/A 100.7 34,51 

60 N/A 101.8 35.26 

•' Orsat "•" Analyzer • Fyrite SuperSat'd 

Vm DP (WC) Tm Ts Max DH (WC) %1SO Vs 

Run Time 1.007 3.73 29.9 °C 191.9 °C Vac. 33.327 mm 8.44 nds 

60.0 mia 35.577 ft 0.15 in 85.8 °F 377.5 °F 6 1.312 in 98.9 27.70 fl/s 

Vmsta Vv%a % H20 Qsd Qsw Qa 

i.004 dscm 0.078 (meas.) 627 dscmm 676 1,100 sere SCOllll aenlnl 

35.456 dscf 2.744 scf 7.2 22,139 dscfm 23,857 scfm 38,828 acfm 

-I.2 

Test Personnel (signature/date) Test Te•m] Leader'•s'tgnature/date) 
Locatiou: GS (Plant 36) Roanoke. VA Ruu 3 

I)ate: 08/22/07 

STACK DATA (EST) 

% Moisture: 7.2 % est. 

Barometric: 30.00 in tlg 

Static Press: 0.12 in WC 

Stack Press: 30.01 in Hg 

%CO2: 3.5 % 

%02: 16.5 % 

%N2/CO: 80.0 % 

Md: 29.22 lb/Ib-mole 

Ms: 28.41 Ib/lb-mole 

EQUIPMENT 

METER BOX: 1376 

Y: 1.054 

DIt@: 1.909 inH20 

P1TOT 1D: PR-14 

Cp: 0.84 

NOZZLE 1D: G-001 

Dn: 0.340 in 

Depth/Width (in): 58.0 58.0 

Stack Area: 23.36 fff 

Start Time: 1:40 AM 

End Time: 12:50 PM 

'STACK DATA (EST) FILTER NO. 

Est. Tin: 86 •F N/A 

Est. Ts: 377 °F 

Est. dP: 0.15 in WC 

Est. Dn: 0.374 inches 

LEAK CHECKS 

Source: DLA Inlet 

Project No.: 2007-0524 

MOISTURE DATA 

Total Liquid Vol. (ml) 

58.7 

K FACTOR 

8.760 

Pre Mid Post 

Leak Rate: 0.001 0.000 cfin 

Pump Vacuum: 12 5 m Hg 

Pitot Tube: Pass Pass 

Volume Corrections 

#1 cf 

#2 cf 

Total cf 

SampleTinle 

(minutes) Dry Gas Meter 

Reading (ft 3) 

Pitot 

DP 

Begin End tin. .,o3 

A-1 0.00 2.50 961.295 0.10 

2 2.50 5.00 962.536 0.11 

5.00 7.50 963,850 0,11 

4 7.50 10.00 965.122 0.12 

10.00 12.50 966.448 0.13 

6 12.50 15.00 967.885 0.18 

7 15.00 17.50 969.550 0.20 

17.50 20.00 971.298 0.21 

B-I 20.00 22.50 973.103 0.11 

2 22.50 25.00 974.400 0. ll 

3 25.00 27.50 975.700 0.12 

4 27.50 30.00 977.040 0.11 

5 30.00 32.50 978.375 0.13 

6 32.50 35.00 979.777 0.14 

7 35.00 37.50 981.220 0.14 

8 37.50 40.00 982.675 0.18 

C-l 40.00 42.50 984.357 0.11 

2 42.50 45.00 985.667 0.11 

3 45.00 47.50 986.980 0.12 

4 47.50 50.00 988.300 0.12 

5 50.00 52.50 989.668 0.17 

6 52.50 55.00 991.330 0.16 

7 55.00 57.50 992.946 0.21 

57.50 60.00 994.746 0.22 

60.00 996.578 

Fiual DGM: 996.578 

Gas Temperatures (°F• 

DGM 

Average Stack 

Arab. Arab. DH (in H•0) (in. Hg) 

89 

90 

91 

91 

90 

92 

92 

92 

90 

91 

91 

91 

92 

92 

92 

92 

91 

93 

Gas Temps (°F) 

Orifice Press. Pump hnp. 

Vac Probe Filter Exit XAD % ISO 

93 363 

94 363 

94 368 

95 372 

95 377 

95 380 

Ideal Actual 

377 0.88 0.89 2 262 

385 0.96 0.97 2 260 

365 0.99 0.99 2 262 

366 1.08 1.08 3 260 

370 1.16 1.17 3 260 

375 1.60 1.60 4 260 

378 1.77 1.78 4 261 

381 1.85 1.86 4 261 

375 0.98 0.98 3 263 

377 0.98 0.98 3 262 

366 1.08 t.07 3 260 

359 1.00 1.00 3 260 

370 1.16 1,17 3 261 

378 1.24 1.25 3 262 

382 1.24 1.24 3 260 

385 1.58 1.58 3 261 

372 0,98 0,99 3 260 

377 0.98 0.98 3 262 

1.09 1.09 3 261 

1.09 1.09 3 260 

1.53 1.54 4 263 

1.44 1.44 3 261 

1.87 1.88 5 261 

1.95 1.96 5 264 

O•sat Analyzer r;, Fyfite 

Vs 

(Ds) 

261 65 N/A 101.2 22.50 

265 65 N/A 102,5 23.71 

263 56 N/A 97.9 23.43 

261 53 N/A 97.7 24.48 

264 52 N/A 102.2 25.55 

265 53 N/A 100.7 30.15 

265 53 N/A 100.5 31.84 

266 53 N/A 101.5 32.68 

262 64 N/A 100•6 23.57 

264 60 N/A 100.7 23.60 

264 57 N/A 98.8 24.48 

262 56 N/A t02.3 23.34 

266 56 N/A 99.4 25.55 

265 57 N/A 99.1 26.64 

266 58 N/A 100.1 26.70 

264 58 N/A 102.3 30.33 

256 66 N/A 101.2 23,53 

264 66 N/A 101.4 23,60 

264 64 N/A 96.8 24.44 

263 62 N/A 100.1 24.44 

264 62 N/A 102.6 29.18 

264 62 N/A 102.9 28,38 

264 62 N/A 100.4 32.61 

266 63 N/A 100.1 33.43 

Super Sat'd 

Vin DP (WC) Tin 

Run Time 0.999 nf 3.56 mm 33.3 °C 

60,0 rain 35.283 |'t 0.14 in 92.0 °F 

V lllsld V•,%ld %t120 Qsd 

0.984 dscm 0.078 scm (meas,) 613 dscmm 

34.767 dscf 2.763 scf 7.4 21,649 dscfm 

Test Personnel (signature/date) 

Ts Max DIt (WC) 

189.7 °C Vac. 32.366 mm 

373.4 °F 5 1.274 iu 

Qsw Qa 

662 scmm 1.072 

23,379 scfm 37,866 

Test 

% SO Vs 

8.23 m/s 

99. 27,02 ft/s 

a C 

acflu 

91/3/o 

'(signa tu re/date) 

-1.2 
Location: GS Brick (Plant 36)-Roanok% VA 

Date: 08/21/07 

Source: DLA Outlet 

Project No.: 2007-0524 

Alley. Asse aS<ss 

Engineering Environmental Health & Safety Surveyieg 

Method Velocity Traverse Data 

Distance from far wall to ontside of port: 76.50 iu. 

Nipple leugth: 5.00 in. 

Depth of Duct (Ds): 71.50 in. 

Cross Sectional Area of Duct (As): 27.88 ft 

No. of ports: 2 

Distance .4,: 14.0 ft. 2.3 Duct Diameters 

Distance B: 70.0 ft. 11.7 Duct Diameters 

Number of t,'averse points torah 12 

Traverse 

point Numbe• 

on a Diamet• 

5 

6 

7 

8 

9 

10 

I1 

12 

LOCATION OF TRAVERSE POINTS 

CIRCULAR STACKS 

Number of traverse ports a diameter 

2 4 6 8 10 12 

14.6 6.7 4.4 3.2 2.6 2.1 

85.4 25,0 14.6 10.5 8.2 6.7 

75.0 29.6 19.4 14.6 1.8 

93.3 70.4 32.3 22.6 17.7 

85.4 67.7 34.2 25.0 

95.6 80.6 65,8 35.6 

89.5 77.4 64.4 

96.8 85,4 75.0 

9l .8 82.3 

97.4 88.2 

93.3 

97.9 

*Percent of stack diameter fiom reside wall to traverse point. 

EXAMPLE CIRCULAR STACK CROSS SECTION DIVIDED INTO 12 

EQUAL AREAS, WITH LOCATION OF TRAVERSE POINTS 

50 

•0 

0 

Minimum number of traverse points for particulate traverses 

Duct Diameters Upstream fl-om Flow Disturbance* (Distance A) 

0.5 1.0 

Higher Number is 1"o1" 

Rectangular Stacks or Ducts 

1.5 

24 25 

2.0 2.5 

Flov, Point ofAi b Type of 

Dislurbance (Bend.Expansion. 

2O 

--] 16 

--] 12 

8 or 9 

2 3 4 5 6 7 8 9 

Duct Diameters Dowostram from Flow Disturbance* (Distance B) 

Traverse 

Point 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

% of Distance fi'om 

Diameter[ inside wall 

4.4 3.15 

14.6 10.44 

29.6 21.16 

70.4 50.34 

85.4 61.06 

95.6 68.35 

Nolcs: 

Distance fror 

outside of 

port 

8.15 

15.44 

26.16 

55.34 

66.06 

73.35 

QA/QC Reviewer 
Location: GS Brick (Plant 36)-Roanoke, VA 

Date: 08/21/07 

Source: I)I,A Outlet 

Project No.: 2007-0524 

•••@• Method 1 Verification of Absense of Cyclonic Flow 

(Section 11.4) 

Engineering Environmental. Health & Safety Surveying 

Sample Point 

1 

2 

3 

4 

5 

6 

7 

AP @ Reference 

0.13 

0.14 

0.15 

Angle (AP=0) 

5 

6 

7 

0.16 6 

0.15 6 

0.12 5 

0.10 

8 0.13 

9 0.16 5 

10 0.16 6 

11 

12 

13 

14 

15 

16 

17 

18 

19 

20 

21 

22 

23 

24 

25 

26 

27 

28 

29 

30 

31 

32 

33 

34 

35 

36 

37 

0. t5 

0.13 

0.14 5.7 

38 

39 

40 

Average 

QA/QC Reviewer 
Location: GS Brick (Plant 36)-Roanoke, VA Source: DLA Ontlet 

Project No.: 2007-0524 

Engineering. Environmental, Health & Safety. Surveying 

Method 3 Gas Analysis Data 

Run 1 Date: 8/22/07 

Analysis Number % CO2 °//o 02 °//o Nz 

1 2.5 16.5 81.0 

2 3.0 17.0 80.0 

3 3.0 17.0 80.0 

Average 2.8 16.8 80.3 

Repeatability (P/F): P P P 

Run 2 Date: 8/22/07 

Analysis Number % COz % O2 % Nz 

1 3.0 16.5 80.5 

2 3.0 16.5 80.5 

3 3.0 16.5 80.5 

Average 3.0 16.5 80.5 

Repeatability (P/F): P P p 

Date: 8/22/07 

% C02 % 02 % Nz 

3.0 16.5 80.5 

3.0 17.0 80.0 

3.0 17.0 80.0 

3.0 16.8 80.2 

P P P 

Run 3 

Analysis Number 

1 

2 

3 

Average 

Repeatability (P/F): 

Acceptability for Orsat Repeat Analysis 

CO2 > 4% + 0.3% 

CO2 < 4% + 0.2'?6, 

O7 > 15%---+ 0.3% 

02 -< 15%--- + 0.2% 

Ambient Check Analysis Typ___e 

02 20.5 % Orsat report to 0.1% 

CO•_ 0.0 % Fyrite report to 0.5% 

QA/QC Reviewer 
Location: GS Brick (Plant 36)-Roanoke, VA Source: DLA Outlet 

Project No. 2007-0524 

ROBERTS 

I•'tCORPORATED 

Engineering. Environmental. Health & Safety. Surveying 

Method 4 Moisture Data 

Contents 

Initial 

Final 

Gain 

Riin 1 Date: 8/22/07 Filter ID: N/A 

IMPINGER VOLUME, •nl 

1 4 5 6 7 8 Total 

H2SO4 NaOH Silica 

100,0 100.0 232.8 632.8 

120.0 100.0 674.0 

2 3 

H2SO4 NaOH 

100.0 100.0 

108.0 102.0 

8.0 2.0 

Impinger Color: Clear 

0.0 

244.0 

11.2 

Silica Gel Condition: )K 

20.0 41.2 

Rnn 2 Date: 8/22/07 Filter ID: N/A 

IMPINGER VOLUME, ml 

1 2 3 4 5 6 7 8 Total 

Contents H2SO4 H2SO4 NaOl-t NaOH Silica 

Initial 100.0 100.0 100.0 100.0 228.8 628.8 

Final 142.0 114.0 100.0 100.0 239.6 695.6 

Gain 42.0 14.0 0.0 

Impinger Color: Clear 

0.0 10.8 

Silica Gel Condition: OK 

66.8 

Contents 

Initial 

Final 

Gain 

alln 3 • Date: 8/22/07 Filter ID: N/A 

IMPINGER VOLUME, lnl 

1 6 7 8 Total 

H2SO4 

t00.0 619.0 

140.0 687.7 

,..__, 

40.0 68.7 

2 3 

H2SO4 NaOH 

100.0 100.0 

114.0 104.0 

14.0 4.0 

4 5 

NaOH Silica 

100.0 219.0 

102.0 227.7 

2.O 8.7 

hnpinger Color: Clear Silica Gel Condition: OK 

QA/QC Reviewer 
Location: GS Brick (Plant 36)-Roanoke, VA Start Tinlc: 8:01 AM 

8/22/2007 Run ]VALII) Date: End "l-imc: 9:06 AM 

A-1 

2 

3 

4 

6 

B-I 

2 

3 

4 

5 

6 

STACK DATA (EST) 

% Moisture: 7.0 % est. 

Barometric: 30.00 in Hg 

Static Press: 0.18 inWC 

Stack Press: 30.01 inHg 

%CO2: 3.5 % 

%02: 16.5 % 

%N2/CO: 80.0 % 

Md: 29.22 lb/lb-mole 

Ms: 28.43 lb/lb-mole 

EQUIPMENT 

METER BOX: 1600 

Y: 1.018 

All @: 2.300 

PITOT ID: MST PR-02 

Cp: 0.84 

NOZZLE ID: G-804 

Dn: 0.375 

Diameter: 71.5 in 

Stack Area: 27.88 f( 

STACK DATA (EST) 

Est. Tin: 85 

Est. Ts: 329 '•I:' 

Est. dP: 0.14 in WC 

Est. Dn 0.373 inches 

Source: DLA Outlet 

Project No.: 2007-0524 

FILTER NO. MOISTURE DATA 

N/A Total Liquid Volume (ml) 

41.2 

K-FACTOR 

16.604 

LEAK CHECKS 

Pre Mid Post 

Leak Rate: 0.002 0.000 

•ump Vacuum: 15 4 

Pitot Tube: Pass Pass 

cfin 

in Hg 

Volume Corrections 

#1 cf 

#2 cf 

Total cf 

Sample Time Dry Gas Meter 

(,ninntes) Reading (ft 3) 

Begin Eud 

0.00 5.00 680.658 

5.00 10.00 684,090 

10.00 15.00 687.660 

15.00 20.00 691.400 

20.00 25.00 695.425 

25.00 30.00 699.260 

30.00 35.00 702.507 

35.00 40.00 705.839 

40.00 45.00 709.430 

45.00 50.00 713.240 

50.00 55.00 717.198 

55.00 60.00 720.915 

60.00 724.077 

Final DGM: 724.077 

Gas Temperatures(°F 

Pitot DGM Orifice Press. Pump 

Vac Tube Average Stack All (in. 1120) (in. 

Arab. Arab. Hg.) 

72 74 Ideal Actual 

0.13 72 351 2.05 2.05 3 

0.13 73 352 2.05 2.05 3 

0.15 74 353 2.37 2.37 3 

0.17 76 354 2.69 2.68 4 

0.15 77 355 2.37 2.38 4 

0.10 79 355 1.59 1.59 3 

0.11 77 348 1.76 1.76 3 

0.13 80 354 2.07 2.07 4 

0.15 81 356 2.39 2.39 4 

0.16 83 357 2.55 2.56 4 

0.14 83 357 2.24 2.24 4 

0.10 84 357 1.60 1.60 3 

Gas Temps 

hnp. 

Probe Filter Exit XAD % ISO 

Vs 

(rps) 

74 76 72 

251 265 65 N/A 99.1 25.24 

265 266 63 N/A 102.9 25.26 

259 266 64 N/A 100.3 27.15 

257 266 63 N/A 101.2 28.92 

255 265 61 N/A 102.4 27.18 

263 265 62 N/A 105.6 22.19 

255 266 67 N/A 103.3 23.17 

262 255 66 N/A 102.3 25.29 

259 266 64 N/A 101.1 27.20 

262 265 64 N/A 101.4 28.1 

257 259 65 N/A 101.7 26.29 

258 260 66 N/A 102.0 22.22 

Orsat i" Anal/zer iJ Fynte Saturated 

W 

Run Time 1.230 •n 

60.0 rain 43.419 ft 

Wlnslci Vv¢$1 

1.203 dscm 0.055 

42.471 dscf 1.939 scf 

AP (in WC) Tm Ts 

3.41 mm 25.7 °C 178,9 °C 

0,13 iu 78.3 °F 354.1 °F 

%H20 Qsd Qsw 

Max AH (in WC) %1SO Vs 

Vac. 54.483 7.91 m/s 

4 2.145 iu 98.0 25.97 ft/s 

Qa 

4.4 

743 dscmm 

26,251 dscfin 

778 scmm 1,230 aclnm 

0.2 

27,459 scfm 43,442 acfm 

QA/QC 
Location: Start Time: 9:52 AM 

Date: End Time: 10:57 AM 

STACK 

% Moisture: 

Barometric: 

Static Press: 

Stack Press: 

%CO2: 

%02: 

%N2/CO: 

Md: 

Ms: 

A-I 

2 

3 

4 

5 

6 

B-1 

2 

3 

4 

5 

6 

GS Brick (Phmt 36)-Roanoke, VA 

08/22/07 Run 2 ]VALID 

DATA (EST) 

5.0 % est, 

30.00 in Hg 

0.18 in WC 

30.01 in Hg 

3.5 % 

16.5 % 

80.0 % 

29.22 lb/lb-mole 

28.66 lb/lb-mole 

EQUIPMENT 

METER BOX: 1600 

Y: 1.018 

AH @: 2.300 in H20 

PITOT ID: MST PR-02 

Cp: 0.84 

NOZZLE ID: G-804 

Dn: 0.375 in 

Diameter: 71.5 in 

Stack Area: 27.88 f12 

STACK DATA (EST) 

Est. Tin: 78 

Est. Ts: 354 

Est. tiP: 0.13 in WC 

Est. Dn: 0.379 inclaes 

Source: DLA Outlet 

Project No.: 2t107-fl524 

FIL•R NO• MOISTURE DATA 

N/A ;Fotal Liquid Volume (ml) 

66.8 

K FACTOR 

16.447 

LEAK CHECKS 

Pre Mid Post 

Leak Rate: t}.002 0.000 

Pump Vacuum: 12 5 

Pitot T.be: Pass Pass 

cfm 

in fig 

Wohlme Correctiolls 

#1 ef 

#2 cf 

Total cf 

Sample Time 

(minutes) Dry Gas Meter 

Reading (ft 31 

Begin End 

0.00 5.00 724.293 

5.00 10.00 727.700 

10.00 15.00 731.820 

15.00 20.00 735.810 

20.00 25.00 739.705 

25.00 30.00 743.325 

30.00 35.00 746.476 

35.00 40.00 750.012 

40.00 45.00 753.575 

45.00 50.00 757.593 

50.00 55.00 761.840 

55.00 60.00 766.110 

60.00 769.523 

Fiual DGM: 769,523 

Pitot 

Gas Te•npcratures (°F) 

DGM Orifice Press. Pllmp 

DP Vac 

Average Stack AH(in. 1120) (in. 

Arab. tlg.) 

(in. H20) Ideal Actual 

0.12 82 355 1.99 1.99 

0.17 84 360 2.80 2.80 

0.16 86 36l 2.64 2.64 

0,15 88 361 2.49 2.49 

0.13 90 361 2.17 2.17 

0.10 90 361 1.67 1.67 

0.13 88 354 2.18 2.18 

0.12 92 359 2.111 2.0t 

0.16 93 360 2.68 2.69 

0.17 94 361 2.85 2.85 

0.18 95 361 3.02 3.02 

0.11 96 360 1.86 1,86 

Gas Temps (°F) 

rap. 

Vs 

Probe Filter Exit XAD % ISO 

(fps) 

3 255 258 66 N/A 99.0 24.2 

4 260 262 60 N/A 100.7 28,91 

4 263 264 58 N/A 100.2 28.06 

4 265 263 58 N/A 100.6 27.17 

4 262 260 56 N/A 100.0 25.30 

3 263 263 58 N/A 99.1 22.19 

4 265 264 65 N/A 97.6 25.19 

4 264 266 61 N/A t01.9 24.27 

5 266 265 61 N/A 99.6 28.05 

5 260 265 62 N/A 102.0 28.93 

5 265 263 64 N/A 99.5 29.77 

4 263 266 65 N/A 101.2 23.25 

Orsat Anal) %• l:x rite Saturated 

AP (in WC) Tm Ts 

Ruu Time 1.281 m 3.57 32.1 °C 181.9 °C 

43.335 dscf 3.144 sef 

60.0 rain 45.230 ft 0.14 in 

Vmstd Vws,a % ItzO 

1.227 dscm 0.089 (meas.) 

6.8 

89.8 °F 359.5 

Max .•11 (in WC) %1SO Vs 

Vac. 60.050 8.16 rigs 

5 2.364 in 100.1 26.79 ft/s 

Qsd Qsx+ Qa Yqa 

743 dscmm 797 1,269 acmm 

-I.5 

26,224 dscfm 28,137 scfm 44,8tl acfm 

QA/QC Reviewer 
Location: GS Brick (Plant 36)-Roauoke, VA 

Date: 08/22/07 Run 3 [VALID 

STACK DATA (EST) 

% Moisture: 7.0 % est. 

Barometric: 30.00 in Hg 

Static Press: 0.18 in WC 

Stack Press: 30.01 in Hg 

%CO2: 3.5 % 

%02: 16.5 % 

%N2/CO: 80.0 % 

Md: 29.22 lb/Ib-mole 

Ms: 28.43 lb/tb-mole 

EQUIPMENT 

A-1 

2 

3 

4 

5 

6 

B-I 

2 

3 

4 

5 

6 

METER BOX: 1600 

Y: 1.018 

AH@: 2.300 in H20 

PITOT ID: MST PR-02 

Cp: 0.84 

NOZZLE ID: G-804 

Dn: 0.375 in 

Start Time: :40 AM Source: DLA Outlet 

End Time: 12:44 PM Project No.: 2007-0524 

STACK DATA (EST) FILTER NO. MOISTURE DATA 

Est. Tm: 90 °F N/A Total Liquid Volume (ml) 

Est. Ts: 360 °F 68.7 

Esl. dP: 0.14 in WC K FACTOR 

Est. Dn: 0,374 inches 16.121 

LEAK CHECKS 

Diameter: 71.5 in 

Stack Area: 27.88 "ft 

Gas Temperatures (°F• 

Pre Mid 

Leak Rate: 0.000 

lump Vacumn: 12 

Pitot Tube: Pass 

Sa•nple Time 

0ninutes) Dry Gas lVleter 

Reading (ft •) 

Begin End 

0.00 5.00 769.790 

5,00 10.00 773,188 

10.00 15.00 776.735 

15.00 20.00 780.603 

20,00 25.00 784.585 

25.00 30.00 788,500 

30.00 35.00 791.735 

35,00 40.00 795.520 

40.00 45.00 799.150 

45.00 50.00 803.010 

50.00 55.00 806.828 

55.00 60.00 810.420 

60.00 813.706 

Final DGM: 813.706 

Post Volume Corrections 

0.000 cfin #1 cf 

4 in Hg #2 cf 

Pass Total cf 

Gas Temps (°F) -----[----'-T• 

Pitot DGM Orifice Press. Pump hnp. •1 

DP Average Stack AH(in. H20) Vac Probe Filter Exit VXAD b/o lSO[ 

" (YSs)•p. a,nb. (in. Hg) 

(ia. n•o) Ideal Actual 

0.12 93 358 1.95 1.95 3 261 254 67 

0.13 94 358 2.12 2.12 3 256 263 60 N/A 98.8 25.35 

0.15 95 359 2.44 2.44 4 259 26( 60 N/A 100.; 27.25 

0.16 96 360 2.60 2.60 4 257 266 61 N/A 99.8 28.16 

0.15 96 359 2.45 2.45 4 252 266 62 N/A 101.3 27.25 

0.10 96 358 1.64 1.63 3 251 266 63 N/A 102.2 22.23 

0,13 95 356 2.13 2.12 4 254 262 66 N/A 105.1 25.32 

0,14 96 357 2.29 2.29 4 261 266 56 N/A 97.0 26.29 

0.15 97 356 2.46 2.46 4 265 266 56 N/A 99.5 27.20 

0.15 98 357 2.46 2.46 4 263 266 57 N/A 98.3 27.21 

0.12 98 356 1.97 1.97 3 265 265 57 N/A 103.2 24.32 

0,10 99 355 1.65 1.65 3 266 266 59 N/A 103. 22.19 

Orsat Analyzer 14 Fyfitc Saturated 

Vm 

Run Time 1.244 1113 

60.0 miu 43.916 ft 

1,178 dscm 0.092 scm 

41,583 dscf 3.234 scf 

AP (in WC) Tm Ts Max AH (in WC) %iSO Vs 

3.37 mm 35.6 °C 180.8 °C Vac. 55,330 mm 7.93 m/s 

0.13 in 96.1 °F 357.4 °F 4 2.178 in 99.2 26.00 ft/s 

% tt_,O Qsd Qs• Qa Vqa 

(meas0, 720 dscmm 775 scram 1,232 acmm 

7.2 25,414 dscfm 27,385 scfm 43,504 acfln 

-I.I 

QA/QC Revim• e, 
Appendix C 
Your Project #: 2007-0524 

Site: GENERAL SHALE 

Attention: Chris Lemay 

E Roberts Alley & Associates 

1931 Central Pky SW 

Suite B 

Decatur, AL 

USA 35601 

Report Date: 2007/09/11 

CERTIFICATE OF ANALYSIS 

MAXXAM JOB #: A791439 

Received: 2007/08/24, 13:30 

Sample Matrix: Impinger Solution 

# Samples Received: 6 

Analyses 

Hydrogen Halides, H2SO4 irnp(26Amod) 

Final Volume of Impinger 

Quantity 

Date Date 

Extracted Analyzed Laboratory Method 

Method 

Reference 

2007/09/07 2007/09/07 BRL SOP-00104 

2007/09/07 2007/09/11 

EPA 26Amod(M26A) 

PM Released by 

Burlington Project Manager 

Total cover pages: 

5555 North Sen'ice Road, Burlington, Ontario, Canada L7LSH7 

Page of 6 

Tel: (905) 332-.8788 TolIFiee: (800) 668-0639 Fa•:(905) 332-9169 
Maxxam Job #: A791439 

Report Date: 2007/09/11 

E Roberts Alley & Associates 

Client Project #: 2007-0524 

Project name: GENERAL SHALE 

Sampler Initials: 

RESULTS OF ANALYSES OF IMPINGER SOLUTION 

Maxxam ID 

Sampling Date 

ANIONS 

-tydrochloric Acid ug 

-lydrofluoric Acid ug 

CONVENTIONALS 

Volume ml 

Volume ml 

Volume ml 

U27842 

2007/08/22 

Units DLA-OUTLI=T-RUN 

01 

U27843 U27878 

2007/08/22 2007/08/22 

DLA-OUTLET-RUN 

02 DLA-OUTLET-RUN03 DL QC Batch 

46000 46000 43000 

23000 24000 21000 

280 

300 

300 

1000 

750 

1354445 

1354445 

1354219 

1354219 

1354219 

RDL Reportable Detection Limit 

QC Batch Quality Control Batch 

U27879 

2007/08/22 

Units DLA-INLET-RUN 

01 

U27880 U27881 

2007/08/22 2007/08/22 

DLA-INLET-RUN 3LA-INLET-RUN 

02 03 

Maxxam ID 

Samplin,cj Date 

ANIONS 

-tydrochloric Acid ug 

Hydrofluoric Acid ug 

CONVENTIONALS 

Volume ml 

Volume ml 

Volume ml 

RDL Reportable Detection Limit 

QC Batch Quality Control Batch 

50000 56000 59000 

360000 370000 360000 

300 

310 

300 

DL 

1000 

7500 

QC Batch 

1354445 

1354445 

1354219 

1354219 

1354219 

5555 North Se•,'ice Road, Burlington. Ontario, Canada L7L 51-t7 

Page 2 of 6 

Tel: (905) 332-8788 Toll Free (800) 668-0639 Fax: (905) 332-9169 
Maxxam Job #: A791439 

Report Date: 2007/09/11 

Test Summary 

E Roberts Alley & Associates 

Client Project #: 2007-0524 

Project name: GENERAL SHAL.E 

Sampler Initials: 

Maxxam ID U27842 Collected 2007/08/22 

Sample ID DLA-QUTLET-RUN 0I Shipped 

Matrix ImpingerSolution Received 2007/08/24 

Test Description 

Hydro.qen Halides, H2SO4 imp(26Amod) 

IFinal Volume of Impinger 

Instrumentation Batch Prepared Analyzed Analyst 

IC/SPEC 1354445 2007/09/07 2007/09/07 LLE 

1354219 2007/09/11 2007/09/11 LLE 

Maxxam ID U27843 Collected 2007/08/22 

Sample ID DLA-OUTLET-RUN 02 Shipped 

Matrix ImpingerSolution Received 2007/08/24 

Test Description 

Hydrogen Halides, H2SO4 imp(26Amod) 

IFinal Volume of lmpinger 

Instrumentation Batch Prepared Analyzed Analyst 

IC/SPEC 1354445 2007/09/07 2007/09/07 LLE 

1354219 2007/09/11 2007/09/11 LLE 

Maxxam ID 

Sample ID 

Matrix 

Test Description 

Hydrogen Halides, H2SO4 imp(26Amod) 

IFinal •olume of Impin.qer 

U27878 Collected 2007/08/22 

DLA-OUTLET-RUN 03 Shipped 

Impinger Solution Received 2007/08/24 

Instrumentation Batch Prepared Analyzed Analyst 

tC/SPEC 1354445 2007/09/07 2007/09/07 LLE 

1354219 2007/09/11 2007/09/11 LLE 

Maxxam ID 

Sample ID 

Matrix 

U27878 Dup Collected 2007/08/22 

DLA-OUTLET-RUN 03 Shipped 

Impinger Solution Received 2007/08/24 

Test Description 

IHydrogen Halides, H2SO4 imp(26Amod) 

Instrumentation Batch Prepared Analyzed Analyst IC/SPEC 1354445 2007/09/07 2007/09/07 LLE 

MaxxamlD U27879 Collected 2007/08/22 

Sample ID DLA-INLET-RUN 01 Shipped 

Matrix ImpingerSolution Received 2007/08/24 

Instrumentation Batch Prepared Analyzed 

IC/SPEC 1354445 2007/09/07 2007/09/07 

Test Description 

Hydrogen Halides, H2SO4 imp(26Amod) 

IFinal Volume of Impinger 

Analyst 

LLE 

1354219 2007/09/11 2007/09/11 LLE 

Maxxam ID U27880 Collected 2007/08/22 

Sample ID DLA-INLET-RUN 02 Shipped 

Matrix ImpingerSolution Received 2007/08/24 

Test Description 

Hydrogen Halides, H2SO4 imp(26Amod) 

IFinal •olume of Impinger 

Instrumentation Batch Prepared Analyzed Analyst 

IC/SPEC 1354445 2007/09/07 2007/09/07 LLE 

1354219 2007/09/11 2007/09/11 LLE 

Page 3 of 6 

5556 North Service Road Burlington. Ontario C•nada L7L 5H7 Tel: (905) 332-8788 Toll Free: (800) 668-0639 Fax: (905) 332-9169 
Maxxam Job #: A791439 

Report Date: 2007/09/tl 

Test Summary 

E Roberts Alley & Associates 

Client Project #: 2007-0524 

Project name: GENERAL SHALE 

Sampler Initials: 

Maxxam ID 

Sample ID 

Matrix 

Test Description 

Hydrogen Halides, H2SO4 imp(26Amod) 

IFinal Volume of Impinger 

U27881 Collected 2007/08/22 

DLA-INLET-RUN 03 Shipped 

Impinger Solution Received 2007/08/24 

Instrumentation Batch Prepared Analyzed Analyst 

IC/SPEC 1354445 2007/09/07 2007/09/07 LLE 

1354219 2007/09/11 2007/09/11 LLE 

.5555 North Se•'ice Road Burlington. Ontado. Canada L7L 5H7 

Page 4 of 6 

Tel: (905) 332-8788 Toll Free: (800) 668-0639 Fax: (905) 332-9169 
Maxxam Job #: A791439 

Repod Date: 2007/09/11 

E Roberts Alley & Associates 

Client Project #: 2007-0524 

Project name: GENERAL SHALE 

Sampler Initials: 

GENERAL COMMENTS 

Results relate only to the items tested. 

5555 North Se£,4ce Road. Burlington. Ontario, Canada L7L 5H7 

Page 5 of 6 

Tel: (905) 332-8788 Toll Free: (800) 668-0639 Faw:(905) 332-9169 
QA/QC 

Quality Assurance Report 

Maxxam Job Number: GA791439 

E Roberts Alley & Associates 

Attention: Chris Lemay 

Client Project #: 2007-0524 

P.O. #: 

Project name: GENERAL SHALE 

Date 

Batch 

Num Init 

1354445 LLE 

Analyzed 

QC Type Parameter yyyy/mm/dd Value %Recovery Units QC Limits MATRIX SPIKE 

(U27878) Hydrochloric Acid 2007/09/07 0, RDL=1000 99 ug 80 120 Hydrofluoric Acid 2007/09/07 0, RDL=750 I01 ug 80- 120 Spiked Blank Hydrochloric Acid 2007/09/07 0, RDL=200 105 ug 90- 110 Hydrofluoric Acid 2007/09/07 0, RDL=150 101 ug 90- 110 Method Blank Hydrochloric Acid 2007/09/07 ND, RDL=200 ug 

Hydrofluoric Acid 2007/09/07 ND, RDL=150 ug 

RPD Hydrochloric Acid 2007/09/07 2.1 % 20 Hydrofluoric Acid 2007/09/07 0.02 % 20 

ND Not detected 

RPD Relative Percent Difference 

SPIKE Fortified sample 

Page 6 of 6 

5555 North Sep4ce Road. Burlington. Ontario, Canada L71_ 5H7 Tel: (905) 332..8788 Toll Free (800) 66B-0639 Fa'x (905) 33Z-9169 

Appendix D 
Method 

Series C•libration 

Orifice Method 

English Meter Units, English 

Filen•me: \\decaturserver\Server\Users\AndrewR\Meter Cals\ICopy (2) •1515 DG•Cal. Console 

Revised: 7/25/95 

8/17/2007 

Barometric (in. 89) 

Theoretic•l Critical (in. 89) 

results, the Actual should Hg gre•ter the Theoretical Critical shown 

critical orifice Coefficient, K', entered in English units, (ft)•3*(deg R)^O.5/((in. Hg)*(min)). 

Volume 

Initial 

(in H20) (min) (cuft) (cuft) 

855.450 

5.00 890.848 

Vol•,e Temps. Final Temps. Orifice Oz'ifice Actual Ambient Temperature 

Inlet Outlet Serial• Coefficient Ii]itial Average 

(cuft) (des F) (des F) (de• F) (des F) (number) (see above) (in Hg) (des F) (des F) (deg F) 

83.0 DG48 0.331 89.5 

5.487 87.0 DG55 

7.058 89.5 

4_865 89.0 89,0 90.0 15,5 

90.0 90.0 90.0 

VOLUME VOLUIdE CALIBRATION 

dH• 

Vm(std) Vm(std) Vcr(std) Vcr(std) V•lue Variation V•lue Value 7ariation 

(c• ft) (liters) (cuft) (liters) (cuft) (number) (number) (in 820) (mm H20)(in 820) 

6.598 -0.009 i•832 46.52 -0.077 

147,9 5.813 0.001 1.902 48.32 -0.006 

1.051 -0.003 1.926 48.92 

131,5 5.182 1.055 

170.8 1.97• 0.063 

Average 

CBlibratlon Y, the ratio the reading the the dry meter, 

acceptable tolerance individual values the •ver•ge +-0,02. 

O•Ifiee C•lib•atzon d89• the differential pressure inches that equates to 0.75 

inches Hg, acceptable tol of the average 
Date: 

Meter Box ID: 

Reference Calibrator: 

Serial No.: 

Cal. Expiration: 

Thermocouple Calibration 

6/6/2007 

1376 

Extech Model 42312 

55000154 

9/23/2007 

(1) Stack 

F R F R % 

0 460 0 460 0.0 

50 510 

100 560 

49 509 0.2 

99 559 0.2 

150 610 150 610 0.0 

300 760 302 762 -0.3 

500 960 503 963 -0.3 

(2) Probe 150 610 151 611 -0.2 

300 760 303 763 -0.4 

(3) Filter 

(4) hnpingers 

(5) Auxiliary 

150 

300 

610 

760 

150 

302 

610 

762 

0.0 

-0.3 

0 460 0 460 0.0 

32 492 30 490 0.4 

68 528 67 527 0.2 

0 460 0 460 0.0 

50 510 48 508 0.4 

100 560 98 558 0.4 

150 610 

300 760 

150 610 0.0 

-0.3 

500 960 -0.1 

(6) DGMInlegOutlet(AmbientCheck) 79 539 0.0 

302 762 

501 961 

79 539 

Note: Accuracy must be within +/- 2% 

°R °F + 460 

Accuracy Reference Temp (°R) Display Temp (°R) X 100 

Reference Temp (°R) 

Completed by: Patti Green 
3[MI•DRTANT 

IMPORTANT 

!!I!!!!!! 

APEX INSTR•4ENTS 

EPA 

522 •eter Calibration 

Pre-Test Orifice M•thod 

English Meter •0X Units, English Factor 

Filenama: X:•AndrewR\Meter Cals\[1600 DG•_5-25-07.x/e]522ORFR5 

Revised: 7/25/95 Version: 

Dat•: 5/25/2007 

Barometric Pressure: 29.72 (in. 

Theoretical Critical 14.02 (in. fig) 

For valid test results, the Vacut•m should be in. Sg gre•ter than •eoretical C•itlcal Vecuum sho•n above. 

The Critical O•ifice Coefficient, K', •st be entered in English units, (ft)^3*(deg 

DRY GAS METER READINGS 

dH 

(in H20) 

0,70 

1.30 

2.2D 

4.20 

6.50 

(rain) (cu ft) [c• ft) (cu ft) (deg F) (d•g •) {deg F) (deg F} (m•b•r) (bee abo•e) [in }Ig) (deg F) (deg F) {deg 

15.00 414,200 420°480 6.200 72.0 73.0 21,5 ?2.0 

421.000 426.582 5.582 73.0 73.0 74.0 0.438 20.5 ?9.0 

i0.00 427.100 7.224 75,0 75.0 76.0 DG63 0.562 83.0 81.5 

5.00 435.500 440.45@ 76.0 76.0 78.0 DG73 83.0 84.0 83.5 

5.00 441.900 6.085 78.0 DGSl 0.959 82.0 83,0 

VOLU• VOLtagE 

CORRECTED CORRECTED CORR N•M/NAL 

(s t•) (std) (std) (std) Vcr 

(c• ft} (liters) (c• ft) (liters) 

6.194 175.4 6.380 180.7 6.510 

5.503 155.8 5.602 158,6 5,759 

7.111 201.• 7,%78 203.3 ?.414 

4,809 138,4 4.969 140,7 5.152 

6.019 170.5 6.•18 173 6.337 

CALIBRATION CALIBRATION FACTOR 

(number) (numbe•) (in H20) 

1.030 2.144 54.46 -0.156 

1.018 2,291 

1.009 -0.009 2.352 0.052 

1,016 2.336 59.33 0.036 

Average y 58.43 

Calibration Factor Y, the ratio of th• reading the calibration the dry meter, 

acceptable toler•ce individual •ralues from the a•erage is +-0.02. 

For Orifice Calibration Factor dH•, the orifice differential inches of that eg•ates of sir 

68 and 29.92 inches of }!g, acceptable tolerance of individual values E•om average is +-0.2. 
Date: 

Meter Box ID: 

Reference Calibrator: 

Serial No.: 

Cal. Expiration: 

Thermocouple Calibration 

6/25/2007 

#1600 

Extech Model 42312 

55000154 

9/23/2007 

(1) Stack 

(2) Probe 

(3) Filter 

(4) Impingers 

(5) Auxiliary 

(6) DGM Inlet/Outlet (Ambient Check) 

460 

50 510 

100 560 

150 

300 

500 

150 

3O0 

150 

300 

610 

760 

960 

610 

760 

610 

760 

0 460 0.0 

49 509 0.2 

99 559 0.2 

151 

3O7 

510 

151 

307 

153 

307 

611 

767 

970 

611 

767 

613 

767 

-0.2 

-0.9 

-1.0 

-0.2 

-0.9 

-0.5 

-0.9 

0 460 0 460 0.0 

32 492 31 491 0.2 

68 528 68 528 0.0 

460 0 460 0.0 

49 509 0.2 

99 559 0.2 

50 510 

100 560 

150 610 152 612 -0.3 

300 760 307 767 -0.9 

5OO 960 510 97O 

84 544 82 542 

-1.0 

0.4 

Note: Accuracy must be •vithin +/- 2% 

°R °F + 460 

Accuracy 

Reference Temp {°R) Display Temp {OR) 

Reference Temp (°R) 

X 100 

Completed by: Paul E. Green 
I"•<" i•, •7 

•j,.• 

Engineering. Environmental, Health & Safety. Su•eying 

E. Roberts Alley & Associates, Inc. 

1931 Central Parkway SW, Suite S 

Decatur, AL 35601 

Phone: (256) 351-0121 

Fax: (256) 351-0151 

ERA&A Project No. 2007-0524 

Nozzle Calibration 

Date: 

Calibrated By: 

8/21/07 

Stacey Cunningham 

G-001 0.340 0.340 0,339 0.00l 0.340 

Notes: 

a: Three different nozzle diameter measure•nents-record to 0.001" 

b: Max Dill" maximt,m difference between any two diameters is 0.004 

c: Average D ave ge ofDI, D2, and D3 
Sample Probe Calibration 

Inspected By: Stacey Cunningham 

Inspection Date: 08/22/07 

Probe ID: PR-14 

E. Roberts Alley & Associates, Inc. 

193 Central Parkway SW, Suite S 

Decatur, AL 35601 

Phone: (256) 351-0121 

Fax: (256) 351-0151 

ERA&A Project No. 2007-0524 

Geometric Pitot Calibration 

Pitot Tube Openings Damaged? Yes iV No 

Pitot Tube Alignment OK? i•" Yes i'' No 

Calibration Required? !•' Yes i• No 

External Tube Diameter (Dr)* Dt =0.375 

*Dr must be between 3/16 abd 3/8 

Base-to-plane opening distances (Pa and Pb)* Pa 0.4375 

*Pa Pb Pb 0.4375 

Pa/Dt 1.17 

(Must be between 1.05 and 1.5) 

Ifpitot does not meet the criteria above, it must be repaired/calibrated in accordance with 

Sections 4.1.2 through 4.15 of Method 2. Baseline coeflr]cient of 0,84 applied to pitots that meet 

inspection criteria. 

Thermocouple Calibration 

Ice 

Ambient 

Boiling H20 

73.0 533.0 74.0 534.0 

Hot Oil 

Specification % Difl•lence 1.5 

1.0 0.2% 

ComlllelltS: 
Locatiou: GS Brick (Plant 36)-Roanoke, VA Source: DLA Oudet 

Project No.: 20t)7-0524 

INCORPORATED 

Engineering, Environmental. Health & Safety. Surveying 

Calibrations 

Nozzle Calibrations 

Date Calibrated By: Run No(s) (initials) 

Nozzle ID 

D1 

Nozzle Diameter iV[ax Average 

Number Difference D 

D2 D3 

inches inches 

0.373 0.376 

inches inches inches 

8/21/07 SC 1-3 G-804 0.375 0.003 0.375 

Three different nozzle diameter measure•nents-record to 0.001 inches. 

Maxxmmn difference between any two diameters is 0.004 inches. 

Pitot Calibrations 

Pitot Tube Calibrated By: Probe Pitot Tube Calibration Date 

(initials) Rull No(s) Opening ID No. 

Damage Alignment Required 

8/22/07 SC 1-3 MST PR-02 No Ok No 

Extenml Tube Diameter (Dr)* 

*Dt nmst be between 3/16 and 3/8 

Dt =0.375 Base-to-plane opening distances (Pa and Pb)* 

Pa 0.4375 Pb 0.4375 *Pa Pb 

Pa/Dt 1.17 Must be belween 1.05 and 1.5 

lfpitot does not meet Ibe criteria above, it must be repaired;calibraled in accordance with Sections 4.1.2 through 4.15 of 

Method 2. Baseline coefficient of 0.84 applied to pilots that meet inspection criteria. 

Probe Thermocouple Calibratiou 

Probe 1D No. 

MST-PR-02 

Reference 

Temperature 

(°F) (°R) 

73.0 533.0 

Indicated 

Temperature 

(°F) (°R) 

75.0 535.0 

Diff;rence 

Temperature 

(°F) 

2.0 

Difference 

t'age Iot 

From: West Martha [Martha.West@generalshale.com] 

Sent: Thursday, August 23, 2007 11:36 AM 

To: Chris LeMay 

Co: Klepper, William 

Snbjeet: General Shale Brick, Roanoke Plant operational data 

Following is the plant operating data for the 8/22/2007 stack test. If you have 

questions, please let me know. 

Brick production 17.7 tons/hr 

Limestone feed rate 140 Ibs/hr 

Coal usage 1,367 Ibs/hr 

Gas usage 6.15 x 103 scf/hr 

DLA Differential Pressure 0.35 in. 

Thank you, 

Martha 

Martha West 

Environmental Engineer 

General Shale Brick, Inc. 

P.O. Box 3547 

Johnson City, TN 37602 

Phone: (423)952-4240 

Fax: (423)952-4160 

file://C:\Company\Projects\General Shale BrickXRoanoke",Roanokc 20{)7 Trip 2 Rctest,G._. 9/13,'20(}7 
Page of 

From: West Martha [Martha.West@generalshale.com] Sent: Thursday, August 23, 2007 11:36 AM 

To: Chris LeMay 

Co: Klepper, William 

Subject: General Shale Brick, Roanoke Plant operational data 

Following is the plant operating data for the 8/22/2007 stack test. If you have questions, please let me know. 

Brick production 17.7 tons/hr 

Limestone feed rate 140 Ibs/hr 

Coal usage 1,367 Ibs/hr 

Gas usage 6.15 x 103 scf/hr 

DLA Differential Pressure 0.35 in. 

Thank you, 

Martha 

Martha IVes¢ 

Environmental Engb•eer 

General Shale Brick, Inc. 

P.O. Box 354 7 

Johnson City, TN 37602 

Phone: (423)952-4240 

Fax: (423) 952-4160 

file://C:\Company\Projects\General Shale Bricl<\Roanoke',,Roanokc 2007 Trip 2 l{elesr, G... 9/13/2007